Bezel-free display tile with edge-wrapped conductors and methods of manufacture

ABSTRACT

Display tiles comprising pixel elements on a first surface of a substrate connected by an electrode, a driver located opposite the first surface, and a connector wrapped around an edge surface of the substrate connecting the driver to the pixel elements. Displays comprised of display tiles and methods of manufacturing display tiles and displays are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation application and claims the benefit ofpriority under 35 U.S.C. § 120 of U.S. application Ser. No. 16/756,692filed on Apr. 16, 2020, which in turn, claims the benefit of priorityunder 35 U.S.C. § 371 of International Application Serial No.PCT/US2018/056018 filed on Oct. 16, 2018, which in turn, claims thebenefit of priority under 35 U.S.C. § 119 of U.S. ProvisionalApplication Ser. No. 62/572,900 filed on Oct. 16, 2017, the contents ofwhich are relied upon and incorporated herein by reference in theirentireties.

FIELD OF THE DISCLOSURE

The disclosure relates generally to display devices, and moreparticularly to bezel-free display tiles comprising an edge-wrappedconductor and methods for manufacturing the same.

BACKGROUND

Displays comprised of a plurality of individual display tiles are usedto manufacture large displays, which are sometimes referred to as tileddisplays. For example, video walls comprised of multiple display tilesare known for their high-impact engagement and stunning visuals, and areutilized in a variety of settings, including retail environments,control rooms, airports, television studios, auditoriums and stadiums.As will be apparent from FIG. 1 , in current displays, the edge portionsof the display tiles and the display device itself are utilized forelectrical leads and various other electronic components associated withthe operation of the display panel, such as driver circuits that caninclude thin film transistor arrays for an active matrix display.Examples of these displays include liquid crystal displays (LCD) andorganic light emitting diode (OLED) displays. This has resulted in flatdisplay panel manufacturers encasing the edge portions within and/orbehind a bezel, which conceals the foregoing electronic components.

FIG. 1 shows a prior art display tile 50, which comprises a firstsubstrate 52 having a first surface 55 and an outer perimeter 56. Thedisplay tile 50 includes rows 60 of pixel elements, each row 60 of pixelelements 58 connected by a row electrode 62 and a plurality of columns70 of pixel elements 58, each column 70 of pixel elements 58 connectedby a column electrode 72. The display tile further includes at least onerow driver 65 that activates the rows 60 of pixel elements 58 and atleast one column driver 75 that activates the columns 70 of pixelelements 58. In the prior art display tile 50, the row drivers 65 andthe column drivers 75 are located on the first surface 55 on the sameside of the pixel elements, requiring a bezel (not shown) to cover therow drivers 65 and the column drivers 75.

For aesthetic reasons, flat panel display makers are trying to maximizethe image viewing area and provide a more aesthetically pleasingappearance by minimizing the size of the bezel surrounding the image onthe display. However, there are practical limits to this minimization,and current bezel sizes are on the order of 3 millimeters to 10millimeters in width.

There have been efforts in the industry to achieve tiled displayscomprised of display tiles with no bezel and seamless zero millimeterbezel (referred to herein as “zero bezel” or “bezel-free”). Bezel-freedisplay tiles allow for vast configurations of tiled displays withoutthe need for irritating black gaps. To achieve a bezel-free displaytile, it can be advantageous to have the pixel elements in closeproximity to the edges of the display tiles. These pixel elements can belocated on the front side of the display tile substrate and the controlelectronics on the back side. As a result, there is a need toelectrically interconnect the front and back sides of the display tilesubstrate.

One way to achieve such interconnects in a display tile substrate madefrom glass is with metallized through glass vias (“TGVs”). Such TGVs canbe used to manufacture a zero bezel microLED display, however, TGVs arefairly expensive to make, at least using current methods which involvelaser damage of each hole (a serial process) followed by etch. The holesthen need to be further processed for metallization.

Implementation of TGVs presents challenges with overall manufacturingprocess sequence. If the front of the tile substrate is to have a thinfilm transistor (TFT) array, a question arises as to when the glass viasare made and metallized. Since TFT array fabrication is traditionallydone on a pristine glass surface, etching and metallization may best bedone after TFT fabrication. As a result, the array must be protectedfrom etch and also be compatible with the metallization technique.

There is a continuing need to provide efficient and effectiveinterconnects on display tiles. It would be desirable to providebezel-free display tiles that could be placed in an array to achieve alarge display that maintains pixel pitch across tile boundaries ofadjacent display tiles without metallized vias.

SUMMARY

A first aspect of the disclosure pertains to a display tile comprising afirst substrate comprising a first surface, a second surface oppositethe first surface and an edge surface between the first surface and thesecond surface, the edge surface defining an outer perimeter; the firstsurface comprising an array of pixel elements arranged in a plurality ofrows of pixel elements and a plurality of columns of pixel elements,each row of pixel elements connected by a row electrode and each columnof pixel elements connected by a column electrode; a row driver thatactivates the rows of pixel elements and a column driver that activatesthe columns of pixel elements, the row and the column drivers locatedopposite the first surface; a plurality of row electrode connectors,each row electrode connector wrapped around the edge surface andelectrically connecting a row electrode, a row of pixel elements and therow driver; and a plurality of column electrode connectors, each columnelectrode connector wrapped around the edge surface and electricallyconnecting a column electrode, a columns of pixel elements and thecolumn driver.

A second aspect of the disclosure pertains to a method of manufacturinga display tile, the method comprising placing at least one driver on afirst substrate having pixel elements on a first surface of the firstsubstrate, the driver placed on a second surface opposite the firstsurface and that can activate the pixel elements; and placing aconnector on an edge surface and extending to the first surface and thesecond surface, the edge surface defining an outer perimeter.

A third aspect of the disclosure pertains to a method of manufacturing adisplay, comprising placing display tiles described herein in closeproximity to each other at respective edge surfaces of the displaytiles.

A fourth aspect of the disclosure pertains to a method of manufacturinga plurality of display tiles comprising stacking a plurality ofsubstrates to provide a stack, each of the plurality of substrateshaving a first surface, a second surface opposite the first surface andan edge surface between the first surface and the second surface, theedge surface defining an outer perimeter; arranging the stack at anangle with respect to a horizontal surface to expose the edge surface;depositing conductive material on the edge surface, the first surfaceand the second surface to form a plurality of row electrode connectorsand a plurality of column electrode connectors; electrically connectingan array of pixel elements arranged in a plurality of rows of pixelelements and a plurality of columns of pixel elements so that there areindividual rows of pixel elements on the first surface of each of theplurality of substrates, the individual rows of pixel elements connectedwith individual row electrodes and individual row electrode connectors;electrically connecting individual columns of pixel elements on thefirst surface of each of the plurality of substrates with individualcolumn electrodes and individual column electrode connectors; andplacing at least one driver on a second surface opposite the firstsurface of each of the plurality of substrates, wherein the driver canactivate the pixel elements.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description can be further understood when readin conjunction with the following drawings.

FIG. 1 is a schematic top perspective view of a prior art display;

FIG. 2 is a top perspective view of a display tile according to one ormore embodiments of the disclosure;

FIG. 3 is a side perspective view of the display tile of FIG. 2 ;

FIG. 4 is a bottom perspective view of the display tile of FIG. 2 ;

FIG. 5 is a top plan view of an array of display tiles providing a tileddisplay according to one or more embodiments of the disclosure;

FIG. 6 is an end view of a flex circuit according to one or moreembodiments of the disclosure;

FIG. 7 is a top plan view of the flex circuit of FIG. 6 ;

FIG. 8 is a side view showing a flex circuit being applied to a displaytile according to one or more embodiments of the disclosure;

FIG. 9 is a top plan view showing conductive coating making electricalcontact with electrodes and a flex circuit on a display tile accordingto one or more embodiments of the disclosure;

FIG. 10 is a partial side view of a flex circuit adhered to a substrateand a driver disposed on an end of the flex circuit according to one ormore embodiments of the disclosure;

FIG. 11 is a partial side view of a flex circuit adhered to a substrateand a driver disposed on an end of the flex circuit wrapped around astandoff according to one or more embodiments of the disclosure;

FIG. 12 shows a substrate that can be used for a display tile that hasbeen processed to have a rounded edge surface according to one or moreembodiments of the disclosure;

FIG. 13 shows a connector applied to a substrate having a square edgesurface and a substrate having a round edge surface according to one ormore embodiments of the disclosure;

FIGS. 14A-E show various edge surface profiles of display tilesaccording to one or more embodiments of the disclosure;

FIG. 15 shows two display tiles having their edges in close proximityaccording to one or more embodiments of the disclosure;

FIG. 16A is a side view showing a sample holder for processingsubstrates to make a plurality of display tiles according to one or moreembodiments of the disclosure;

FIG. 16B is an enlarged section from FIG. 16A;

FIG. 17 is a side perspective view showing a sample holder forprocessing substrates to make a plurality of display tiles according toone or more embodiments of the disclosure;

FIGS. 18A-C show a substrate being processed to manufacture a displaytile according to one or more embodiments of the disclosure; and

FIG. 19 is a bottom plan view of a display tile connected to a centralprocessing unit according to one or more embodiments of the disclosure.

DETAILED DESCRIPTION

Described herein are display tiles, methods of manufacturing displaytiles, tiled displays comprising display tiles and methods ofmanufacturing tiled displays utilizing the display tiles describedherein. As used herein, the terms “display” and “display device” areintended to encompass all devices capable of displaying visual content,including, but not limited, to computers, including laptops, notebooks,tablets and desktops, mobile telephones, wearable displays such aswatches, televisions (TV) and video displays comprised of multipledisplay tiles such as video walls and stadium display screens. Each ofthe foregoing devices includes many component parts including thephysical case or cabinet in which individual components may reside,circuit boards, circuit elements such as integrated electroniccomponents, and of course the display panel itself.

Currently, these display panels are flat display panels comprisingliquid crystal display elements, organic light emitting diode (OLED)display elements, plasma display elements, or micro-LED displayelements, and of course the glass or plastic substrates that many ofthese elements are disposed on and/or enclosed by. Micro-LED, also knownas microLED or mLED, is an emerging flat panel display technology.Micro-LED displays have arrays of microscopic LEDs that are part of theindividual pixel elements. Compared to LCD technology, micro-LEDdisplays offer greater contrast, much faster response times, and useless energy. The fabrication of micro-LED displays typically involvesmass transfer of micro-LEDs (<100 micrometers in width and length) ontoa substrate with patterned circuit (driving with passive matrix format)or transistors (driving with active matrix format), depending on thedesign and products. Thus, as used herein, the display tiles anddisplays or display devices described herein can be used in liquidcrystal displays, LED displays, OLED displays, plasma displays, andmicro-LED displays.

Furthermore, the display tiles and tiled displays described herein canbe utilized with both passive matrix (i.e., no TFT array) and activematrix (TFT array) regardless of the particular type of pixel elementused to form the display. As is understood in the art, the differenttypes of displays utilize different types of pixel elements to providethe display. For example, in an OLED display, the pixel elementcomprises rows and columns of “emitters” and TFTs connected by row andcolumn drivers that activate the pixel elements, while with LCDdisplays, the pixel element comprises rows and columns of liquid crystal(LC) light valves and transistors connected by row and column driversthat activate the pixel elements. The descriptions provided herein aresimplified such that each pixel element comprises one color pixel (e.g.,blue), whereas in reality each pixel element is comprised of one or moresubpixels (e.g., red, green and blue). The individual pixel elements canbe addressed by a unique row/column combination utilizing knowntechnology. The pixel elements are the components required for thefunctioning of individual pixels in the display and can include emittingelements or light valves and TFTs.

Referring now to FIGS. 2-4 , a display tile 150 is shown, whichcomprises a first substrate 152 comprising a first surface 155, a secondsurface 157 opposite the first surface 155 and an edge surface 154between the first surface 155 and the second surface 157, the edgesurface 154 defining an outer perimeter 156 of the display tile.

The display tiles 150 described herein according to one or moreembodiments can comprise a substrate 152 of any suitable material, forexample, a polymeric substrate or a glass-based substrate having anydesired size and/or shape appropriate to produce a display tile. Thefirst surface 155 and second surface 157 may, in certain embodiments, beplanar or substantially planar, e.g., substantially flat. The firstsurface 155 and the second surface 157 may, in various embodiments, beparallel or substantially parallel. The substrate 152 according to someembodiments may comprise four edges as illustrated in FIGS. 2-4 , or maycomprise more than four edges, e.g. a multi-sided polygon. In otherembodiments, the display tile 150 may comprise less than four edges,e.g., a triangle. By way of a non-limiting example, the substrate 152may comprise a rectangular, square, or rhomboid sheet having four edges,although other shapes and configurations are intended to fall within thescope of the disclosure including those having one or more curvilinearportions or edges.

In certain embodiments, substrate 152 may have a thickness d1 of lessthan or equal to about 3 mm, for example, ranging from about 0.1 mm toabout 3 mm, from about 0.1 mm to about 2.5 mm, from about 0.3 mm toabout 2 mm, from about 0.3 mm to about 1.5 mm, from about 0.3 mm toabout 1 mm, from about 0.3 mm to about 0.7 mm, or from about 0.3 mm toabout 0.5 mm, including all ranges and subranges therebetween.

As used herein, the term “glass-based substrates” is used in thebroadest sense to include any object made wholly or partly of glass.Glass-based substrates include laminates of glass and non-glassmaterials, laminates of glass and crystalline materials, andglass-ceramics (including an amorphous phase and a crystalline phase).Unless otherwise specified, all glass compositions are expressed interms of mole percent (mol %).

The glass-based substrate used to manufacture the display tile cancomprise any glass-based material known in the art for use in displaydevices. For example, the glass-based substrate may comprisealuminosilicate, alkali-aluminosilicate, borosilicate,alkali-borosilicate, aluminoborosilicate, alkali-aluminoborosilicate,soda lime, or other suitable glasses. Non-limiting examples ofcommercially available glasses suitable for use as a glass substrateinclude, for example, EAGLE XG®, Lotus™, and Willow® glasses fromCorning Incorporated.

The first surface 155 of the display tile 150 comprises an array ofpixel elements 158 arranged in a plurality of rows 160 of pixel elements158 and a plurality of columns 170 of pixel elements 158. Each row 160of pixel elements 158 is connected by a row electrode 162, and eachcolumn 170 of pixel elements 158 is connected by a column electrode 172.It will be understood, that the rows 160 and columns 170 of pixelelements that intersect include some of the same pixel elements 158.Thus, there are not two separate sets of pixel elements 158, but onearray of pixel elements 158 containing pixel elements 158 that are bothconnected to separate row and column electrodes. The display tileaccording to one or more embodiments comprises at least one row driver165 that electrically activates the rows 160 of pixel elements 158 andat least one column driver 175 that activates the columns 170 of pixelelements 158, the row drivers 165 and the column drivers 175 are locatedopposite the first surface 155. In the embodiment shown in FIGS. 2-4 ,the row drivers 165 and the column drivers 175 are located on the secondsurface 157 of the substrate 152. In other embodiments, the row drivers165 and the column drivers 175 can be located on a separate structuredisposed opposite the first surface 155, such as on a separate substrate(not shown) or other suitable structure.

As will be appreciated, the row drivers 165 and the column drivers 175must be connected to the row electrodes 162 and the column electrodes172 to activate the pixel elements 158. A plurality of row electrodeconnectors 164 are provided, and each row electrode connector 164 iswrapped around the edge surface 154 and electrically connects a rowelectrode 162, a row 160 of pixel elements 158 and a row driver 165. Thedisplay tile shown further comprises a plurality of column electrodeconnectors 174, each column electrode connector 174 wrapped around theedge surface 154 and electrically connecting a column electrode 172, acolumn 170 of pixel elements 158 and the column driver 175. In theembodiment shown, each row driver 165 is shown as connecting three rows160 of row electrodes to pixel elements 158, and each column driver isshown as connecting four columns 170 of column electrodes 172 to pixelelements 158. It will be understood that this arrangement is forillustration purposes only, and the disclosure is not limited to anyparticular number of row drivers, column drivers or number of rowelectrode or column electrodes respectively driven by the row driversand column drivers. For example, the electrode connectors can exist ononly one or multiple edge surfaces 154 based on the specific displaydesign and layout. Furthermore, the disclosure is not limited to anyparticular number of pixel elements 158 or arrangement of pixel elements158 on the first surface 155 of the substrate 152.

The display tile 150 is free of a bezel around the outer perimeter 156of the display tile 150, and as such, provides a bezel-free display tile150 or a zero bezel display tile 150. To achieve a seamless displaywhere the pixel pitch across the tile-to-tile seam is approximatelymatched to that within the tile, the pixel elements are ≤10 mm, ≤5 mm,≤3 mm, ≤1 mm, 0.5 mm, or ≤0.3 mm from the edge of the display tilesubstrate. The pixel elements on neighboring tiles are then registeredto each other with placement error ≤50%, ≤30%, ≤10%, ≤5% of a pixelpitch.

Any suitable connector type can be utilized to provide the row electrodeconnectors 164 and the column electrode connectors 174. Also, all of theelectrode connectors do not need to be of the same type or design. Inone or more embodiments, at least one row electrode connector 164 and atleast one column electrode connector 174 comprises a flex circuit 300 asshown in FIGS. 6 and 7 . An exemplary flex circuit 300 comprises aflexible polymeric film 302 and a conductor 304. In the embodimentshown, a plurality of conductors 304 are shown arranged in rows. Theflex circuit 300 may further comprise an adhesive 306 that adheres theflex circuit 300 to the edge surface 154 of the substrate 152. In theembodiment shown, the adhesive 306 is an adhesive layer that isintegrally formed with the flex circuit. In some embodiments, the flexcircuit 300 may comprise the flexible polymeric film 302 and theconductor(s) 304, and an adhesive may be separately applied. The flexcircuit 300 has a total thickness in a range of 10 micrometers to 150micrometers, for example, in a range of 10 micrometers to 50 micrometersor in a range of 10 micrometers to 20 micrometers. Suitable materialsfor the polymeric film 302 include, but are not limited to materialsselected from the group consisting of polyimide, polyester, polyethylenenaphthalate (PEN), polyethylene terephthalate (PET), and polyether etherketone (PEEK). The adhesive 306 can comprise a pressure sensitiveadhesive, for example, a pressure sensitive adhesive comprising amaterial selected from the group consisting of a polyimide, an acrylic,an acrylate, ethylene vinyl acetate, butyl rubber, nitrile, andsilicone. The flex circuit 300 can also be adhered to the edge surface154 by use of a curable or liquid adhesive. The conductor 304 can beselected from copper and silver, other metals or other conductivematerial capable of forming individual electrode traces, and can beformed by any suitable method such as deposition, plating, printing,thick films, etc. Examples of conductive materials not based ondeposited films include Ag ink, CNT, and other solution-based materials.The overall dimension of the flex circuit can vary, and ultimately willbe determined by the size of the display tile. A suitable width “W” canbe from 10 mm to 500 mm, for example 50-100 mm, and the conductors canhave a width “W_(c)” in the range between 20 micrometers and 500micrometers wide, for example 100 micrometers. Spacing “S” between eachconductor ranging from 10 micrometers to 500 micrometers, for example 50micrometers.

FIG. 8 shows a display tile 250 comprising a substrate 252 on a table290 and a flex circuit 300 including an adhesive 306, a conductor 304and a polymeric film 302 being applied to and edge surface 254 of thedisplay tile 250. An applicator 292, which can be in the form of a slabof material such as a substrate, which can be a glass substrate or othersuitable material presses the flex circuit against the edge surface 254to adhere the flex circuit 300 to the substrate 252. A cutting device294, such as a razor, knife, laser or other suitable cutting instrumentcan cut the flex circuit 300 to an appropriate height, which may beequal to the thickness of the substrate 252, or greater than thethickness of the substrate 252. Electrodes and electrode connectors canbe on individual substrates or on multiple substrates at one time. Forexample, multiple substrates can be stacked together with or withoutinterleaf or spacer materials or other methods of providing a spatialgap between substrates. The electrodes can then be manufactured acrossthe entire stacked edge face at the same time. Different processes canbe used to align the stack of edge faces, and different electrodeforming methods will have different edge alignment tolerances. Afterforming the electrode across multiple substrates, the substrates can beseparated which may require cutting the electrode material that bridgesacross each substrate face.

The display tile shown in FIGS. 2-4 shows the row electrode connectors164 directly connected to the row electrodes 162 and the columnelectrode connectors 174 directly connected to the column electrodes172. In some embodiments, each row electrode 162 can be electricallyconnected to a row electrode connector 164 such as a flex circuit 300 bya conductive coating 296 on the first surface 255 and each columnelectrode 172 can electrically connected to a column electrode connector174 such as a flex circuit 300 by a conductive coating 296 on the firstsurface 255 as shown in FIG. 9 , which shows only connection of rowelectrodes 162 to flex circuits. Similarly, the electrode connector canbe connected to electrical structures on the second surface by use of asimilar conductive coating. As examples, the conductive coating can beformed by solution-processing, printing, lamination, or vacuumdeposition methods. While not shown in FIG. 9 , the conductive coating296 will typically overlap with the row electrode 162 and the flexconductor 304.

Referring now to FIGS. 10 and 11 , an embodiment is shown in which aflex circuit 300 is attached to an edge surface 254 of a substrate 252of a display tile 250 by adhesive 306, and including the conductor 304and polymeric film 302. The conductive coating 296 on the first surface255 of the substrate 252 connects the flex circuit 300 to a rowelectrode (not shown in FIG. 10 ). A row driver 265 is disposed oppositethe first surface 255 and is disposed on the flex circuit 300. FIG. 11is a configuration similar to FIG. 10 is shown, except there is a secondsubstrate in the form of standoff 298 opposite the first substrate 252disposed opposite the first surface 255. The second substrate can be inthe form of a standoff 298, which may be made of a material such asrubber or a polymer and provides a curved surface for the flex circuitto transition from the edge. In one or more embodiments, there is atleast one standoff 298 for column drivers along a long edge surface 254of the substrate 252 and at least one standoff 298 for row drivers alonga short edge. In some embodiments, there is a standoff 298 on all fouredge surfaces 254 of the substrate, for example, in a situation wherethere is a desire was to cut the length of rows and columns by half(i.e., running from each edge to the middle rather than all the wayacross the substrate 252). In the embodiment shown in FIG. 11 , the rowdriver is sandwiched between the flex circuit 300 and the standoff 298,and disposed on both the flex circuit and the standoff 298. In someembodiments, the driver 265 can be soldered to the flex circuit 300, andthe flex circuit 300 can be bonded to the standoff 298 with an adhesive.

Referring now to FIGS. 12 and 13 , the display tile substrate 252 can beshaped so that the corner 254 a between the first surface 255 and theedge surface 254 and corner 254 b between the second surface 257 and theedge surface 254 are such that the first corner 254 a and the secondcorner 254 b do not include a 90 degree angle or an undercut angle. Asshown in FIG. 12 , the edge surface 254 comprises a curvedcross-section. FIG. 13 shows the unprocessed substrate 252 with rowelectrode connectors 264 wrapped around the edge surface 254 to thefirst surface 255 and the second surface 257. On the left hand side ofFIGS. 12 and 13 , the corners 254 a and 254 b are square or comprise 90degree angles, while the substrates on the right hand side afterprocessing have an edge surface 254 that comprises a curvedcross-section. As examples, it is possible to have one corner 254 ashaped to be non-90 degree or non-undercut. It is also possible to haveboth corners 254 a and 254 b shaped. If both corners are shaped, 254 aand 254 b do not need to have the same profile.

FIGS. 14A-E show various configurations of edge surfaces 254 that can beutilized in one or more embodiments, with FIG. 14A showing a square edgesurface 254 comprising 90 degree angles, FIG. 14B showing a curvedcross-section or rounded edge surface 254, FIG. 14C showing a polygonalcross section of edge surface 254 with no 90 degree angles, FIG. 14Dshowing an edge surface 254 comprising an angle less than 90 degrees,and FIG. 14E showing a slightly rounded edge surface 254. If the edgeprofile is rounded, the radius is in the range of 1-500 micrometers,1-200 micrometers, 1-100 micrometers, 1-50 micrometers, 1-20micrometers, or 1-10 micrometers. The various edge surfaces can beformed using forming techniques such as etching to have an edge surfacethat comprises an etched surface. The substrate edge surface can be anyarbitrary shape that enables continuous electrode manufacture oradhesion. According to one or more embodiments, the edge shaping will becontained within ≤200 um, ≤100 um, ≤50 um, ≤20 um, ≤10 um, ≤5 um fromthe substrate edge along the first surface. In one or more embodiments,edge shapes include corners between the first/second surface and theedge surface with a curved cross-section having a radius of ≤200 um,≤100 um, ≤50 um, ≤20 um, ≤10 um, ≤5 um. The various edge surfaces can beused with printed electrodes and/or connectors, patterned electrodesand/or connectors and/or flex circuit connectors. Where a flex circuitis used as a connector, the edge of the flex circuit may be within adistance of ≤100 um, ≤50 um, ≤20 um, ≤10 um, ≤5 um, ≤1 um from thesubstrate first or second surface.

The profile does not need to be symmetrical, and the edge profile alongthe perimeter of the substrate at the edge surface does not need to bethe same. The edge surface 254 can be formed by edge grinding using agrinding wheel to provide an edge surface that comprises an edge-groundsurface. The edge surface 254 can be formed by plasma-treating the edgesurface to shape the edge surface so that the edge surface comprises aplasma-treated surface. The shaped substrate edge surfaces can becreated by processes such as acid etching via dipping, aerosol-jetting,or other application process, localized thermal process, laserpolishing, and plasma can be used to create rounded edge surfaces. Otheradditive processes such as edge coatings, sol-gel or deliberate edgebumps or oscillations can also be used to achieve the same purpose.Moreover, the edge surface coating process can also be used toencapsulate or protect conductors. An optical index matching coating canfacilitate seamless tiling of display tiles. Various edge conductordeposition processes such as printed seed layer then plating, directprinted conductor, laser induced metallization, pen-dispensing and othertechniques can be used to form the various electrodes and connectors.

In specific embodiments, the substrate profile can be shaped by using anetching process. After a substrate is formed into tiles and the surfacemasked as necessary, the edge profile of the display tiles would berounded, and flaws from the tile forming process reduced by exposure toan appropriate acid dipping solution. Surface masking could be achievedthrough a printing approach such as screen printing, aerosol jetting,etc. The etching of the tile edges could also be directly achieved via aprinting process (e.g. aerosol jetting). In this approach, an acidic,water soluble polymer (e.g. polyacrylic acid) is applied to the desiredlocation of the tile edge followed by exposure to a source of F ions(e.g. ammonium fluoride) which could also be via a printing process. Theacidic polymer and the F ions will react to locally form HF to etch theglass and produce a water soluble product (ammonium fluorosilicate) thatcan be rinsed off. The extent of the etching will be governed by theamount of the reactants applied and time. The use of printing approachesmentioned above could be used along the entire length of the tile edgesto produce a uniform profile and provide a process of printing the rowelectrode connectors and the column electrode connectors. It can alsoallow for a variable profile, by varying the areas exposed to the acidor amounts of reactants in amounts and/or locations to produce varyingprofiles. This localized etching of the edge could be further extendedto etch grooves for the electronic traces themselves. This localizedapproach could also be applied to the entire substrate to create groovesfor the tile forming process itself and potentially reduce any sharpedges created during tile forming, reducing the amount of additionalprocess to achieve the desired edge profile.

According to one or more embodiments, cost savings can be realized byeliminating glass hole drilling, copper metallization and overburdenremoval. This reduces the overall process complexity and also canimprove the overall yield. Shaping the substrate edge surfaces will alsoprevent the discontinuity of edge conductor coating by creating smoothercorner edges instead of sharp edges. In addition, shaping the substrateedges can also improve the strength of glass to improve the mechanicalreliability and minimize the yield loss during tiling of display tilesfor form display. Shaping edges by edge coating processes can alsofacilitate seamless tiling with appropriate index matching material.

In specific embodiments, atmospheric pressure jet plasma could be usedfor glass edge treatment, using gas such as clean dry air (CDA), or N₂with or without Ar, or adding H₂ into CDA or N₂ to generate more heat tolocally soften glass so that it could re-flow and “heal” cracks on edgesurfaces. The glass edge can be made very smooth generating little or noparticle shedding. During AP jet plasma glass edge treatment, glass islocally melted and cracks are all “healed” that benefit bothsignificantly less particle generation and improved edge strength. APjet plasma treated edge can have particle density of less than 10count/0.1 mm². Such low particle could benefit device performance andyield. Another benefit of AP jet plasma treated edge is improved edgestrength, and in one trial, an atmospheric pressure plasma treated edgehad a strength of ranging from 200-230 MPa.

In some embodiments, the substrate edge profile can be shaped using anadditive approach. For example, a solution-based coating such as asol-gel can be used. A thermally or UV-curable sol gel can be applied tothe edge of the glass via a dip coating of syringe dispensing method.The surface tension of the material should allow for the formation of acurved edge after curing—similar to a bullnose edge. For a dip coatededge, it is likely that the material would also be deposited on thesurfaces adjacent to the edge. This would result in a coating/curvaturethat would completely cover the corner, thus eliminating the sharp edge.

According to one or more embodiments, the various edge shapingtechniques described above, substrate edge strength will be improved andtherefore benefit the mechanical reliability. Hot wire heating of theedge can also improve edge strength. Edge coating or flame deposition ofSiO₂ could also help to fill the cracks to improve the overallmechanical reliability of display tiles.

FIG. 15 shows an embodiment in which a substrate 352 which can be usedto provide a display tile as shown in FIGS. 2-4 has an edge surface 354that is non-linear and comprises a plurality of recessed areas 359 thatprovide a space for row electrodes 362 or column electrodes (not shown)when display tile substrates 352 are placed in close proximity to eachother. The recessed areas 359 provide pockets or gaps that provide anarea for the electrodes 362 to reside when display tiles are arranged toprovide a tiled display. In one or more embodiments, adjacent edgesurfaces may have different profiles or surfaces. Any type of electrodeor electrode connector such as the flex circuits described herein can bedisposed in the recessed areas.

The shaping the glass-based substrate edge surfaces to make electrodeson the edge surfaces as described above can simplify the processes andsave manufacturing cost for manufacturing micro-LEDs. By doing so, themicroLED display can be designed with appropriate electrical layoutinstead of using TGV glass, and the connection between microLEDs onglass surface and IC drives or other components on the back can still berealized by wrapped edge connector electrodes. Moreover, bettermechanical reliability can be obtained with edge shaping, and seamlesstiling of display tiles can also be achieved with appropriate opticaladhesive coating on the edges for both index matching and protection theedge electrodes.

One or more of the row electrodes, the column electrodes, the rowelectrode connectors and the column electrode connectors can comprise aconductive coating, conductive layer or a conductive ink. Suchconductive coatings, conductive layers and conductive inks can beapplied by a variety of processes such as electroplating, electrolessplating, printing, aerojet printing, thin film deposition, thick filmdeposition, and ink jet printing. In one or more embodiments, theconductive coatings, layers or inks comprise a conductive metal such ascopper or silver, and may be in the form of fine particles such asmicrometer-sized particles or nanosized particles. Suitable conductivecoating and inks can be obtained from Henkel AG & Co.(http://www.henkel-adhesives.com/conductive-inks-coatings-27433.htm).

The display tiles described herein can be used to manufacture a tileddisplay as shown in FIG. 5 , which shows a display 400 comprising atleast a first display tile 150, for example as shown in FIGS. 2-4 . Atiled display can comprise multiple or a plurality of display tiles 150arranged in an array, where each display tile is in close proximity toan adjacent display tile 150 substrate 152. As used herein, “in closeproximity” refers to the substrates that are part of the tiled displayare separated so that the pixel pitch (spacing between pixels) acrossthe tile-to-tile seam is ≤150%, ≤120%, ≤110%, ≤105%, or ≤101% of a pixelpitch exiting within the tile. According to embodiments of thedisclosure, the edge wrapped electrode connectors allow for the displaytiles to be placed in close proximity to maintain the pixel pitch. Thedisplay 400 can be any type of display selected from the groupconsisting of a liquid crystal display (LCD), a light emitting display(LED), a micro LED, an electrophoretic display, an e-paper display, andan organic light emitting display (OLED). In some embodiments, thedisplay comprises a micro LED and the pixel elements are located within500 micrometers, 400 micrometers, 300 micrometers, 200 micrometers, or100 micrometers from the edge surface of each display tile, and methodscan be utilized where the pixel elements are within 500 micrometers or200 micrometers from the edge surface.

Another aspect of the disclosure pertains to methods of manufacturingdisplay tiles as shown in FIGS. 2-4 above. The method comprises placingat least one driver on a first substrate that activates pixel elementson a first surface of the first substrate with the driver on a secondsurface opposite the first surface. The method also comprises placing aconnector on an edge surface and extending to the first surface and thesecond surface, the edge surface defining an outer perimeter. The methodcan be varied to provide various configurations as discussed above withrespect to the display tiles described herein.

In an embodiment, the first surface comprises an array of pixel elementsarranged in a plurality of rows of pixel elements and a plurality ofcolumns of pixel elements, the method further comprising connecting eachrow of pixel elements with a row electrode; and electrically connectingeach column of pixel elements with a column electrode, wherein the atleast one driver comprises a row driver that activates the plurality ofrows of pixel elements and a column driver that activates the pluralityof columns of pixel elements, the row driver and the column driverlocated opposite the first surface.

In an embodiment, the method further comprises electrically connectingeach row electrode, each row of pixel elements and the row driver with arow electrode connector wrapped around the edge surface; andelectrically connecting each column electrode, each column of pixelelements and the column driver with a connector wrapped around the edgesurface

In some embodiments of the method, each row electrode connector and eachcolumn electrode connector comprises a flex circuit including a flexiblepolymeric film and a conductor, the method further comprising adheringthe flex circuit to the edge surface. The flex circuit can furthercomprise an adhesive, and adhering comprises applying pressure to theflex circuit to adhere the flex circuit to the edge surface. The methodcan include utilizing the various thicknesses and material describedabove. In some embodiments, the method includes electrically connectingeach row electrode to a row electrode connector by applying a rowconductive coating in contact with the row electrode connector and therow electrode and electrically connecting each column electrode to acolumn electrode connector by applying a conductive coating in contactcolumn electrode conductor and the column electrode.

An embodiment of the method includes stacking of a plurality ofsubstrates to provide a stack, each of the plurality of substrateshaving an edge surface, and adhering the flex circuit to each of theedge surfaces of each of the plurality of substrates. In someembodiments, the second surface is on the flex circuit, and furthercomprising wrapping the flex circuit around a standoff disposed opposedthe first surface.

Some method embodiments further comprise shaping the edge surface sothat a first corner is formed between the edge surface and the firstsurface and a second corner is formed between the edge surface and thesecond surface, and the first corner and the second corner do notcomprise a 90 degree angle or undercut angle. In some embodiments, themethod comprises forming a plurality of column electrode connectors andforming a plurality of row electrode connectors comprises forming aplurality of layers of conductive material. Some embodiments compriseforming a non-linear edge surface comprising a plurality of recessedareas. Such embodiments may include disposing at least one of the rowelectrode connectors and at least one of the column electrode connectorswithin a recessed area. In some embodiments, forming the row electrodeconnectors and column electrode connectors may be formed by a methodselected from printing using conductive ink, vacuum depositing theconductive coating, solution coating the conductive coating, orlaminating the conductive coating.

Another aspect of the disclosure pertains to methods for mass producingdisplay tiles. Referring now to FIGS. 16A-B and 17, one embodiment, amethod of forming a plurality of display tiles comprises stacking aplurality of substrates 552 to provide a stack, each of the plurality ofsubstrates having a first surface 555, a second surface 557 opposite thefirst surface 555 and an edge surface 554 between the first surface 555and the second surface 557, the edge surface 554 defining an outerperimeter and arranging the stack at an angle with respect to ahorizontal surface to expose the edge surface. Arranging the stack at anangle with respect to a horizontal surface can include standing thestack on one edge so that the stack is perpendicular to the horizontalsurface. In some embodiments, arranging the stack at an angle includestilting the stack in a first direction as shown in FIG. 16A at an angle(e.g. 45-85 degrees) with respect to a horizontal surface 510 to exposethe edge surfaces 554. The method further comprises depositingconductive material 513 on the edge surface 554 the first surface 555and the second surface 557 of each of the substrates 552 in the stack toform a plurality of row electrode connectors and a plurality of columnelectrode connectors. It will be understood that deposition on the firstsurface 555 may occur in a first step when the stack is tilted in afirst direction and then deposition on the second surface 557 may occurwhen the stack is tilted in a second direction. The method according tosome embodiments includes an array of pixel elements arranged in aplurality of rows of pixel elements on the first surface of each of theplurality of substrates, such as the rows shown in FIGS. 2-4 , andelectrically connecting an array of pixel elements arranged in aplurality of rows of pixel elements and a plurality of columns of pixelelements so that there are individual rows of pixel elements on thefirst surface of each of the plurality of substrates, the individualrows of pixel elements connected with individual row electrodes andindividual row electrode connectors, such as shown in FIGS. 2-4 . Themethod of some embodiments further comprises electrically connectingindividual columns of pixel elements and a single column electrodeconnector with a column electrode, such as the column electrodes shownin FIGS. 2-4 . The method further comprises placing at least one driverthat activates the pixel elements on a second surface opposite the firstsurface of each of the plurality of substrates, for example, in aconfiguration as shown in FIGS. 2-4 ,

The method shown in FIGS. 16A-B and 17 in some embodiments furthercomprises tilting the stack in a second direction as shown in FIG. 16Bat a second angle (e.g. 45-85 degrees) with respect to a horizontalsurface 510 and depositing the conductive material 513. Thus, as shownin FIG. 16A, the plurality of substrates in a stack are shown tilted tothe left on an edge surface, and a coating applicator 517 appliesconductive coating to the edge surfaces 554 of the substrates. Asuitable applicator can be a printer or an aerosol jet or a pendispenser. Dispensing of conductive material can be carried out with theprogrammed path line to apply on desired region with seed layer or anappropriate design fixture to rotate the substrate for dispensingprocess step. In FIG. 16B, to aid in the conductive material 513covering the second surface 557 to form a conductor that wraps aroundthe edge surface 554 from the first surface 555 to the second surface557, the substrates 552 are tilted to the right at the second angle withrespect to the horizontal surface 510, and then the applicator 517applies conductive coating to the substrates 552 in the stack. Thisprocess enables the formation of a plurality of row electrode connectorsand a plurality of column electrode connectors that wrap around the edgesurface and contact the first surface and the second surface of each ofthe plurality of substrates. As shown in FIGS. 16A and 17 , in someembodiments the substrates 552 are placed in a holder 519 to hold thesubstrates at an angle with respect to horizontal surface 510. FIG. 17shows an alternative version of a sample holder 619 having separators621 that keep the substrates spaced apart and in a stacked relationshipfor forming conductive coatings as shown in FIG. 16A. Note that in thesample holder 619 of FIG. 17 , the substrates would have to be removedand placed back in the sample holder 619 to form a conductive coatingthat wraps around the edge surface 554 to the first surface 555 and thesecond surface 557 of the substrates 552.

Manufacture of a plurality of row electrode connectors and a pluralityof column electrode connectors that wrap around the edge surface andcontact the first surface and the second surface of each of theplurality of substrates can utilize a variety of methods. There aremultiple methods that can be used to fabricate electrodes around asubstrate edge surface according to one or more embodiments. These aredescribed in more detail below.

In one embodiment, forming a printed seed layer and plating (e.g.,electroplating or electroless plating) can be utilized to manufactureelectrodes that wrap around the edge surface. Patterning a polymer-basedpaste with silver (or other conductive species) nanoparticles made byfollowed by electroless plating (or electroplating) plating copper canbe used obtain copper lines to manufacture electrodes. A pattern can becreated manually using a mask that exposes the perimeter of thesubstrate on the order of 2 mm, 4 mm or 10 mm. Spin coating, forexample, at 2000 rpm for 60 seconds can be used to apply a paste, whichcan be cured by ultraviolet light and/or by thermal cure, for example at180° C. for 100 minutes. Electroless deposition of copper can then beperformed at an appropriate time and temperature, e.g. 50° C. for 30minutes or 60 minutes to provide a suitable thickness, e.g., 3micrometers or 5-6 micrometers. Electrodes manufactured in this mannerhad a measured resistivity is 0.3-0.5Ω with 1-3 centimeters in length.Other methods can likewise produce edge connector resistivities of ≤10,≤5, ≤2, ≤1, ≤0.5, ≤0.2, ≤0.1Ω for a ≤10 mm length as formed around theedge of the substrate connecting the first and second surfaces.

Another method that can be used to manufacture electrodes that wraparound the edge surfaces of substrates is laser induced metallization.This method is somewhat similar to the deposition of seed layerfollowing by plating; however, the difference in this technique is theuse of laser 690 to activate a seed (catalyst) layer 692 for followingmetallization. A simplified schematic in FIGS. 18A-C illustrates such aprocess. Using this technique, a pattering region 694 can bethree-dimensional with arbitrary surface features so that a pattern tomanufacture an electrode can be completed in one step rather thanmultiple steps when compared with a two-dimensional coating process. Theprocess can be performed with a programmed path line to apply the laser690 on a designed region for pattering. Instead of moving the laser 690with respect to the substrate 652, an appropriate design fixture can beused to rotate the substrate 652 during a laser pattering step. A samplemade using this technique to manufacture 80 micrometer wide Cu linescould be used to manufacture wrap around electrodes.

In one or more embodiments, metal nanoparticles in photoresist can beused to manufacture electrodes by mixing photoresist with metalnanoparticles for conductor (e.g., Cu) seed layer patterning.Photoresist has light-sensitive property. It can be formed by patterncoating on glass surface by exposure under ultraviolet light. A thinlayer of silver nanoparticle coating can be employed as a catalyst whichenables deposition of a copper seed layer on a substrate surface byplating such as electroless plating. Atmospheric pressure plasma can beutilized to remove photoresist selectively by a mask. A wet electrolessdeposition copper process can be conducted after defining a silvernanoparticle coating on a substrate front, back and edge surfaces,followed by electroplating thicker copper on the seed layer.

In one or more embodiments, another method that could be used tomanufacture wrap around electrodes is laser 3D pattering by coatingglass sheet with a conductor such as copper or silver including wholeedge surface and then utilize 3D laser to remove and define the linepattern of the conductive layer. By doing so, a wet process of copperelectroless plating could be used to ensure the conductor can bedeposited on not only both two surfaces but also whole edge surface. Inone embodiment, a silane modification method with Pd/Sn catalyst can beutilized to activate glass surface prior conductor electroless plating.Using a series of wet processes, a substrate is immersed in silane, thencatalysis and activation solutions, and then through electroless platingof the conductor. This way, the entire substrate would be coated with auniform conductor seed layer (e.g., about 100-200 nanometers inthickness). A 3D laser can be utilized to perform three dimensionalpatterning similar to the method shown in FIGS. 18A-C. Conductor film ata non-defined area can be removed by laser. A 3D laser is able to scanand record the profile of 3D subjects. Therefore, it can be used forpatterning a conductor film across a substrate edge surface tomanufacture electrodes that wrap around edge surfaces of substrates.

Thus, manufacturing of the plurality of row electrode connectors and themanufacturing of the plurality of column electrode connectors on each ofthe plurality of substrates can comprise masking each of the pluralityof substrates to form exposed areas on the first surface, the secondsurface and the edge surface and depositing conductive material on theexposed areas on each of the plurality of substrates to form a patternof row electrode connectors and column electrode connectors. Depositingcan comprise depositing a paste containing silver particles and platingcopper on the paste containing silver particles. In one or moreembodiments, manufacturing the plurality of row electrode connectors andmanufacturing the plurality of column electrode connectors on each ofthe plurality of substrates can comprise depositing the conductivematerial on each of the plurality of substrates, plating the conductivematerial with copper, and irradiating the substrate with a laser beam toform a pattern of row electrode connectors and column electrodeconnectors. The irradiating can occur before or after copper plating. Insome embodiments, forming the plurality of row electrode connectors andcolumn electrode connectors on each of the plurality of substratescomprises a process selected from the group consisting of one or more ofdepositing conductive material on the substrate with an aerosol jet toform a pattern of row electrode connectors and column electrodeconnectors, an additive process such as printing conductive material,and a subtractive process such as etching. In specific embodiments,forming the plurality of row electrode connectors and column electrodeconnectors on each of the plurality of substrates comprises depositingconductive material on each of the plurality of the substrates with anaerosol jet to form a pattern of row electrode connectors and columnelectrode connectors. During such forming, the edge surface of each ofthe plurality of substrates is selected from a curved edge surface, anedge-ground edge surface, a plasma treated edge surface and a polygonaledge surface that comprises angles greater than 90 degrees.

FIG. 19 shows an embodiment of a display tile 750 that can be used tomanufacture a tiled display. A substrate 752 has row drivers 765 andcolumn drivers 775 on the second surface 757 that are connected by rowelectrode connectors 764 and column driver connectors 774 to pixels onthe opposite side of the substrate 752 (as shown in FIGS. 2-4 ). Ribboncables 780 connect the row drivers 765 and the column drivers 775 to aCPU 782 on a printed circuit board 784. Generally, the CPU can controlan image displayed on a display tile by controlling the voltagessupplied to each row driver and column driver in a manner to provide animage on the display tile. The individual pixel elements can beaddressed or activated by a unique row/column combination controlled bythe CPU 782 utilizing known technology. In some embodiments, the CPU 782is configured to send the value of each pixel element to its respectiverow and column driver with those drivers actually providing theappropriate voltage. In a specific embodiment, row drivers 765 are onrow electrode connectors 764 in the form of a flex circuit as describedabove along one edge and column drivers 775 are on column driverconnectors 774 in the form of a flex circuit along an adjacent edge ofthe substrate 752. The row drivers and column drivers can be soldered tothe flex circuit. The row drivers together can have a pin for each rowof pixels and the row electrode connector provides a conductor for eachof those pins to connect to their respective rows of pixel, and thecolumns can be configured similarly.

It will be appreciated that the various disclosed embodiments mayinvolve particular features, elements or steps that are described inconnection with that particular embodiment. It will also be appreciatedthat a particular feature, element or step, although described inrelation to one particular embodiment, may be interchanged or combinedwith alternate embodiments in various non-illustrated combinations orpermutations.

It is also to be understood that, as used herein the terms “the,” “a,”or “an,” mean “at least one,” and should not be limited to “only one”unless explicitly indicated to the contrary. Thus, for example,reference to “a light source” includes examples having two or more suchlight sources unless the context clearly indicates otherwise. Likewise,a “plurality” or an “array” is intended to denote “more than one.” Assuch, a “plurality of light scattering features” includes two or moresuch features, such as three or more such features, etc., and an “arrayof microstructures” includes two or more such microstructures, such asthree or more such microstructures, and so on.

Ranges can be expressed herein as from “about” one particular value,and/or to “about” another particular value. When such a range isexpressed, examples include from the one particular value and/or to theother particular value. Similarly, when values are expressed asapproximations, by use of the antecedent “about,” it will be understoodthat the particular value forms another aspect. It will be furtherunderstood that the endpoints of each of the ranges are significant bothin relation to the other endpoint, and independently of the otherendpoint.

The terms “substantial,” “substantially,” and variations thereof as usedherein are intended to note that a described feature is equal orapproximately equal to a value or description. For example, a“substantially planar” surface is intended to denote a surface that isplanar or approximately planar.

Unless otherwise expressly stated, it is in no way intended that anymethod set forth herein be construed as requiring that its steps beperformed in a specific order. Accordingly, where a method claim doesnot actually recite an order to be followed by its steps or it is nototherwise specifically stated in the claims or descriptions that thesteps are to be limited to a specific order, it is no way intended thatany particular order be inferred.

Various modifications and variations can be made to the materials,methods, and articles described herein. Other aspects of the materials,methods, and articles described herein will be apparent fromconsideration of the specification and practice of the materials,methods, and articles disclosed herein. It is intended that thespecification and examples be considered as exemplary. It will beapparent to those skilled in the art that various modifications andvariations can be made without departing from the spirit or scope of thedisclosure.

What is claimed is:
 1. A display tile comprising: a first substratecomprising a first surface, a second surface opposite the first surfaceand an edge surface between the first surface and the second surface,the edge surface defining an outer perimeter; the first surfacecomprising an array of pixel elements arranged in a plurality of rows ofpixel elements and a plurality of columns of pixel elements, each row ofpixel elements connected by a row electrode and each column of pixelelements connected by a column electrode; a row driver that activatesthe rows of pixel elements and a column driver that activates thecolumns of pixel elements, the row and the column drivers locatedopposite the first surface; a plurality of row electrode connectors,each row electrode connector wrapped around the edge surface andelectrically connecting a row electrode, a row of pixel elements and therow driver; and a plurality of column electrode connectors, each columnelectrode connector wrapped around the edge surface and electricallyconnecting a column electrode, a columns of pixel elements and thecolumn driver, wherein when any edge surface of the display tile isplaced in close proximity to an adjacent display tile of a tile display,a pixel pitch across a tile-to-tile seam of the tile display isapproximately matched to that within the display tile.
 2. The displaytile of claim 1, wherein the display tile is free of a bezel around theouter perimeter.
 3. The display tile of claim 1, wherein each rowelectrode connector and each column electrode connector comprises aconductive coating, conductive layer or conductive ink deposited byelectroplating, electroless plating, printing, aerojet printing,deposition, or ink jet printing.
 4. The display tile of claim 3, whereinthe conductor is selected from copper and silver.
 5. The display tile ofclaim 3, wherein the row and the column drivers are on the secondsurface of the first substrate.
 6. The display tile of claim 3, whereinthe second surface is on a second substrate.
 7. The display tile ofclaim 6, wherein the second substrate is in a stacked arrangement withthe first substrate.
 8. The display tile of claim 3, wherein the firstsubstrate comprises a glass-based substrate.
 9. The display of claim 8,wherein a thickness d₁ of the glass-based substrate ranges from about0.1 mm to about 3 mm.
 10. The display tile of claim 3, wherein theconductive coating, conductive layer, or conductive ink comprises metalnanoparticles.
 11. The display tile of claim 1, wherein the secondsurface is on the first substrate and the edge surface is shaped so thata first corner is formed between the edge surface and the first surfaceand a second corner is formed between the edge surface and the secondsurface, and the first corner and the second corner do not include a 90degree angle or undercut angle.
 12. The display tile of claim 11,wherein the edge surface is comprises a curved cross-section.
 13. Thedisplay tile of claim 11, wherein the edge surface comprises a polygonalcross-section.
 14. The display tile of claim 11, wherein the edgesurface comprises an etched surface.
 15. The display tile of claim 11,where the edge surface comprises an edge-ground surface.
 16. The displaytile of claim 11, wherein the edge surface comprises a plasma-treatedsurface.
 17. The display tile of claim 11, wherein the edge surface isnon-linear and comprises a plurality of recessed areas.
 18. The displaytile of claim 17, wherein at least one of the row electrode connectorsand at least one of the column electrode connectors are disposed withina recessed area.
 19. A display comprising a first display tile asdefined by claim
 1. 20. The display tile of claim 19, wherein thedisplay comprises a micro LED and the pixel elements are located within500 micrometers from the edge surface.
 21. A display comprising thesecond display tile as defined by claim 1 in close proximity to thefirst substrate.
 22. The display of claim 21, wherein the display isselected from the group consisting of a liquid crystal display (LCD), alight emitting display (LED), a micro LED, electrophoretic, e-paper, andan organic light emitting display (OLED).